Method for producing a patterned sheet or film having a predetermined surface characteristic

ABSTRACT

A method for producing a lenticular material having a predetermined surface characteristic of high quality and definition formed on one side thereof is disclosed. The method includes the steps of providing a rotating, engraved cylindrical roll, advancing a material along a predetermined path of travel while directing one surface of the material into contact with a peripheral surface of the rotating, engraved cylindrical roll, applying to the peripheral surface of the roll a coating of a uncured resin, such that the coating is located about the roll and beneath the material, controlling the thickness of the coating, curing the resin coated about the material, and directing the material with the cured resin thereon away from the rotating cylindrical roll.

CROSS-REFERENCED TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 10/999,427, filed on Nov. 30, 2004, and entitled “APPARATUS ANDMETHOD FOR PRODUCING A PATTERNED SHEET AND/OR FILM HAVING APREDETERMINED SURFACE CHARACTERISTIC,” the content of the aforesaidapplication is relied upon and incorporated by reference in itsentirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to an apparatus and method forproducing a composite material having a predetermined surfacecharacteristic formed thereon. More particularly, the present inventionrelates to an apparatus and method for producing a rigid compositematerial sheet or a flexible web having at least one patterned reliefsurface of high quality and definition which is particularly useful forproducing high quality optical components such as lenticular sheetsand/or webs for use with pictures and photographs.

2. Description of the Related Art

In the commercial industry, it is often desirable to impart visualeffects such as three dimensionality or motion characteristics uponpackages or labels of consumable products and the like. Due to expenseand ease of design, regular print advertising was the pre-eminent andpreferred form used on consumables. Regular print advertising isaccomplished by printing, two-dimensional, non-movable information usingwords and pictures on packaging, labels, billboards, signs and the like.While some conventional print advertisements and packaging areinteresting, most are not. Thus, consumers' attention is not attractedto the fullest extent possible. To obviate this problem, the use ofproducts having lenticular effects has become increasingly popular. Areverse printed lenticular web has the ability to attract ones attentionby presenting an image that has depth, morphing characteristics, and/orcan appear to have movement or the capacity to flip from one image toanother. By way of example, a package or label having a printedlenticular web image on a store self has the ability to attract onesattention for a longer period of time than comparable non-lenticularpackages.

Known lenticular lenses, or micro lenses, as used in imaging aretypically elongated, lineal or dot patterned across an entiretransparent web such that an image may be seen therethrough with thedesired visual effect. The lenses can be either convex or concave inconfiguration. In addition, some lenses can be elliptical in shape.Typically, the lenses have a pre-determined radius of curvature and apre-determined uniform pitch or repeat pattern. Lenticular lenses aregenerally thin, transparent lenses that are flat on one side and includea plurality of parallel, linear, side by side lenticules—elongate orconvex lenses—on a second side. Typically, an image is printed on theflat side to create a desired visual effect of the image when viewedthrough the lenticules on the opposing side. The combination of thelenses and an image is referred to as a “lenticular assembly”.

Prior art lenticular assemblies are typically manufactured from acontinuous thin, flexible web. Manufacture of lenses may be performed ina variety of ways. Generally, lens shapes are engraved on a precisionengraving and diamond turning machines into special metal cylinders andpolished to a high luster. The lenses are then index/step and repeatengraved to extremely high accuracies measured in the millionths of aninch onto the thin flexible web using an extrusion process. Thereafter,the images to be used are produced by combining or interlacing aselected image on a computer such that the image is produced in a mannerready for printing. Once interlaced, the image is reverse printed on therear or back, planar side of the lenticular material produced. Reverseprinting is accomplished by any conventional method by any conventionalprinting means. Subsequent to the reverse printing the lenticularassembly is complete.

By way of a specific example, U.S. Pat. No. 4,420,502 to Conleydiscloses an apparatus and method for producing a flexible sheetmaterial having a predetermined surface characteristic of high qualityand definition formed on one side thereof. The apparatus of the U.S.Pat. No. 4,420,502 invention comprises first and second rotating rollswhich are mounted on a generally horizontally extending axis with theperipheral surfaces thereof closely spaced from one another to form anarrow gap corresponding to the desired overall thickness of thecomposite sheet. The second rotating roll has a peripheral surface of apredetermined texture corresponding to the desired surfacecharacteristic to be produced in the sheet. A base web of predeterminedthickness less than the narrow gap is directed onto the peripheralsurface of the first roll and is advanced along an arcuate path aroundthe periphery of the first roll and then through the narrow gap betweenthe first and second rolls. The base web, upon passing through thenarrow gap, is then directed around the second roll and along apredetermined arcuate path around the periphery thereof. A flowableuncured actinic radiation curable thermosetting resin is directed behindthe narrow gap between the first and second rolls and into contact withthe exposed surface of the base web so that a coating of the resin isapplied to the base web and is carried with the base web through thenarrow gap to this position the coating, upon emerging from the gap,beneath the base web and in contact with the peripheral surface of thesecond roll. Then actinic radiation is directed through the base web andonto the coating to cure and harden the coating while in contact withthe patterned surface of the second roll. The base web is then directedaway from the second roll to separate the cured and hardened coatingfrom the roll and thus produce a sheet with a predetermined surfacecharacteristic of high quality and fine definition accuratelyreproducing the surface texture of the second roll.

The above described methods of manufacture for lenticular materialsuffers a number of shortcomings. First, and most importantly, the U.S.Pat. No. 4,420,502 patent fails to teach of an apparatus and methodwhich is useful for the production of thick, rigid lenticular sheets aswell as flexible, thin carrier webs. Rather, the U.S. Pat. No. 4,420,502patent only teaches of an apparatus useful with flexible, thin carrierwebs. Noticeably too, the 4,420,502 patent fails to disclose a doctorblade or other device which is used to meter the coating on theengraving roll for curing and transferring the pattern to the stablecarrier web.

In addition, the use of rigid lenticular sheets are rapidly becomingpopular, due the need for products, such as signs and billboards, to bemore stable and resistant to environmental conditions, such as inclementweather. Similar to the manufacture of the thin flexible webs, variousmethods of manufacture for thick, lenticular sheets exist. However, aswith the thin, flexible webs, conventional methods provide material withless than accurate reproductions of the engraved, patterned roll.Moreover, less stability results from the extrusion of the sheets. Forexample, when a wide sheet material is desired or required, theextrusion process is undesirable as more distortion of the sheet occursdue to the fact that the product must be cooled and pulled down theline. Currently, known art fails also to provide a machine or methodwhich serves the dual purpose of producing either a flexible materialweb or a rigid sheet material having a predetermined characteristicthereon operable for use with lenticular applications.

It is therefore apparent, that there exists a need for an apparatus andmethod capable of producing a stable patterned rigid sheet or continuousflexible thin web which does not vary in dimensions; which has a moreexacting reproduction of the pattern from the engraved cylinder; andwhich provides the ability to produce wider patterned sheets or webswith stability and exactness; both thick rigid patterned sheets, up to ¼inch and thin flexible patterned sheet, down to 0.001 inch or less.

BRIEF SUMMARY OF THE INVENTION

To achieve the foregoing and other objects, and in accordance with thepurposes of the invention as embodied and broadly described herein, thepresent invention provides various embodiments of an apparatus andmethod for producing a rigid patterned sheet and/or flexible weboperable for use with lenticular displays and the like. In variousembodiments, the present invention can produce either thick rigid sheetsor thin, flexible webs operable for use with commercial packagingproducts, signs and billboards, and/or the like. The present inventionprovides significant advantages over the prior art by eliminating theneed for utilizing distinct machines for the production of rigid sheetmaterial and the production of flexible webs or rolls. The presentinvention also provides the capability of producing a stable patternedsheet which does not vary in dimensions and which has a more exactingreproduction of the pattern engraved from the cylinder. Small amountssuch as a few lineal feet or just one sheet can be made which has notbeen possible heretofore.

In various embodiments, the present invention provides an apparatus andmethod for producing a patterned sheet and/or film that has stablecharacteristics and exacting, uniform dimensions for use with commercialproducts such as for example, flooring tiles or roll stock, signage,displays, art, labels, fleet graphics and vehicle decoration, anyreverse printed or laminated to images, wall coverings, wall panels,murals, projection screens, televisions and computer monitors, packagingsuch as labels, boxes, bags and/or the like.

The apparatus and method described herein is useful in the production ofmaterials comprising a variety of patterns such as, for example,lenticular patterns such as elongated lenses; fly eye or dot structures;prismatic; holographic; fresnel; pattern in specific areas.

In one exemplary embodiment of the present invention, the apparatus andmethod for production of a rigid sheet having a predeterminedcharacteristic thereon includes a feed side, a wind up side, anengraved, patterned cylinder, cylindrical nip rolls or guides, a UVlamp, a UV reservoir pan, light shields and a doctor blade forcontrolling the coating thickness of the rigid sheet. In operation, therigid composite sheet is directed across the feed side through a firstset of nip rolls and then around the peripheral surface of the engraved,patterned cylinder. As the sheet crosses the engraved, patternedcylinder, it is coated with a uncured resin and then exposed to UVradiation from the UV lamp, such that the resin cures and the pattern onthe cylinder is transferred to the sheet. Thereafter, the sheet isdirected through a second set of nip rolls and across the wind up side.

In another exemplary embodiment of the present invention, the apparatusand method for production of a flexible web having a predeterminedcharacteristic thereon includes a feed side, a wind up side, anengraved, patterned cylinder, cylindrical nip rolls or guides, a UVlamp, a UV reservoir pan, light shields, a flexible thin web feed roll,a flexible thin web unwind roll, a flexible thin web take up roll, aflexible thin web wind up roll, and a doctor blade for controlling thecoating thickness of the flexible thin web. In operation, the flexibleweb is directed from the unwind roll across the feed side, through thefirst set of nip rolls, around the feed roll and then around theperipheral surface of the engraved, patterned cylinder. As the webcirculates the feed roll, it is coated with an uncured resin.Thereafter, it crosses the engraved, patterned cylinder, is exposed toUV radiation from the UV lamp, such that the uncured resin cues therebyhaving the pattern on the cylinder is transferred to the web.Thereafter, the web is directed around the take up roll through a secondset of nip rolls and across the wind up side to the wind up roll.

In both exemplary embodiments, the light shields prevent damage from theUV lamps to the material prior to crossing the engraved pattern.Further, the UV reservoir pan contains an uncured resin such that as thecylinder rotates it's peripheral surface passes through the pan.Thereafter, as the material comes in contact with the cylinder the resinis compressed between the cylinder and the material during UV exposure.The doctor blade is provided and controls the coating thickness on theengraved patterned cylinder such that accurate reproductions of thepattern can be transferred to the sheet or web.

Optionally, the newly patterned web may be laminated to a thick rigidsheet by using the apparatus of the present invention. The optionallamination of a rigid sheet is performed by the addition of laminatornip rolls, a take up of patterned sheet with pressure sensitive adhesivethereon, directing a rigid sheet through the nip rolls such that thepatterned sheet is adhered thereto, and a release liner take up roll.

In an alternative embodiment of the present invention, a base framehaving a first and second end including a plurality of adjustable legs,a plurality of adjustable cross members and at least one vertical memberis provided. Attached to the respective first and second ends of thebase frame at the adjustable legs are a feed roll and a take up roll fora flexible web. Further, attached to the cross members in apredetermined location is an engraved patterned cylinder. The cylinderis situated such that the peripheral surface thereof extends above thebase frame. Located on the cross members in predetermined locations area plurality of adjustable and repositionable nip or guide rolls fordirecting the flexible web from the feed roll through the apparatus,around the engraved, patterned cylinder and through the nip rolls to thetake up roll. Located above the engraved, patterned cylinder and affixedto the vertical member is a UV lamp for radiating the flexible web as itcrosses over the peripheral surface of a coated cylinder. By radiatingthe flexible web and coated cylinder, the patterned relief of thecylinder is transferred to the web. At least one UV reservoir pancontaining an uncured resin and doctor blade is provided such that thecoating thickness of the cylinder is controlled, thereby ensuring thatthe patterned transferred to the sheet or web is accurate and moreexact.

In order to accommodate a rigid sheet material, the adjustable nip rollsof the apparatus are repositioned such that the peripheral surface ofthe nip rolls is coincident with the peripheral surface of the cylinder.Thereafter, the rigid sheet is advanced through the nip rolls, acrossthe cylinder and through the opposing nip rolls.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the features and advantages of the invention having been stated,other features and advantages will become apparent as the descriptionproceeds, when taken in connection with the accompanying drawings, inwhich

FIG. 1 is a schematic view showing one exemplary embodiment of theapparatus of this invention as used with a rigid composite sheetmaterial;

FIG. 2 is a schematic view showing one exemplary embodiment of theapparatus of this invention as used with a flexible thin web material;

FIG. 3 is a schematic view showing another exemplary embodiment of thepresent invention wherein a flexible web is laminated to a rigid sheet;

FIG. 4 is a schematic view of an alternative embodiment of the apparatusof present invention as used with a flexible thin web material; and

FIG. 5 is a perspective view of the alternative embodiment of theapparatus of present invention of FIG. 4 as used for flexible webmaterial.

FIG. 6 is a perspective view of the alternative embodiment of theapparatus of the present invention of FIG. 4 as used for rigid sheetmaterial.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, if any, in which exemplaryembodiments of the invention are shown. However, this invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein. These exemplary embodiments areprovided so that this disclosure will be both thorough and complete, andwill fully convey the scope of the invention to those skilled in theart. Like reference numbers, if any, refer to like elements throughoutthe various drawings.

The present invention provides various embodiments of an apparatus andmethod for producing rigid composite lenticular sheets and/or thin,flexible film webs having a predetermined characteristic on one surfacethereof. As is well known and understood in the art, lenticular lensmaterial utilizes rows of simple and commonly dome shaped lenses or“lenticules” in combination with a line form or interlaced image, tocreate a desired visual effect. As used herein, the term “lenticularmaterial” is intended to include any optical sheet, roll, film or webthat is suitable for use in the printing arts and has a substantiallytransparent quality. Material compositions of such lenticular materialmay include, for example and without limitation, any acrylic,polycarbonate, polypropylene, polyester, polyethylene,polyvinylchloride, and polystyrene that UV light or electron beams willpass through. All such compositions are considered to be polymericmaterials and are synonymous therewith. In a preferable example, thelenticular material produced by the apparatus and method hereindisclosed generally comprises a flat side and a lenticulated sideincluding lenticules. An image is affixed, or reverse printed, to theflat side of the lenticular material thereby allowing a viewer to seethe desired visual effect from the lenticulated side. The resultingproduct is an improved lenticular assembly that provides advantages overthe prior art without the shortcomings.

In all of the exemplary embodiments shown and described throughout thespecification, the present invention generally includes a structurehaving a table-like configuration with an open center provided with a atleast one connection means for supporting at least one pair of nip orguide rolls and at least one engraved, patterned cylinder. As isunderstood by those skilled in the art, the term “engraved, patternedcylinder” is meant to include cylinders that are fabricated by firstdesigning a cutting tool, such as a stylus, with a desired lens shape.The cutting tool is preferably made of a diamond or carbide, however, itwill be understood by those in the art that any hard material suitablefor engraving cylinders may be used. The shape of the cutting tool isdictated by the desired visual effect. Once the cutting tool isdesigned, the inverse lens shape is engraved into pre-selected portionsof a metal cylinder using any known, conventional method of engraving,thereby forming a plurality of inverse lens arrays or patterns.Subsequent to engraving the cylinder, it is operable for use with thepresent invention in the transferring of the inverse lens pattern to thelenticular material by the extrusion embossment method herein described.

Referring now to FIG. 1, a preferred embodiment of the disclosedapparatus and method of the present invention is shown wherein a rigid,composite sheet material 100 is produced. Generally, the apparatus 10comprises a base frame 12 having a generally table like configurationincluding an upper surface 14 and opposing sides, 16 and 18respectively, defining a central or intermediate opening 20. Theopposing sides 16, 18 operate to function as a feed side 16 and a takeup side 18. The base frame 12 also includes a plurality of legs, 22 and24 respectively, for supporting the base frame 12 at a pre-determinedheight and adjustable, connecting means (not shown) operable for usewith a plurality of rolls. The legs 22, 24 are preferably adjustable inheight such that they can be raised or lower as desired or required.Further, the central or intermediate opening 20 may be widened ornarrowed as required. Disposed within the intermediate opening 20 andmounted to the base frame 12 along a substantially horizontal axis bythe adjustable, connecting means is an elongate engraved, patternedcylindrical roll 26 for embossing the lenticular material 100 with apre-determined relief pattern.

The cylindrical roll 26 preferably has respective shafts 25 extendingfrom opposite ends thereof, and the shafts 25 are mounted into theconnecting means. The connecting means are preferably pillow blocks thatare adjustable in position by suitable means, such as a threaded shaftor spacers (not shown). By suitable adjustment of the connecting means,the cylindrical roll 26 can be raised or lowered, but is preferablyfixed, in position relative to the upper surface 14 of the base frame12. Also, connected to the roll 26 is suitable drive means (not shown),such as a gear train or belt train, for cooperating with the shafts 25and rotating the roll 26 at a pre-determined speed in a predetermineddirection. In the embodiment illustrated herein, the cylindrical roll 26is mounted such that a peripheral surface 28 thereof is substantiallyplanar with the upper surface 14 of the base frame 12.

At least one pair, and preferably two pairs, of nip or guides rolls, 34and 36 respectively, are mounted to the base frame 12 on the opposingsides 16,18. The nip rolls 34,36 are generally of an elongatecylindrical shape and have a substantially smooth peripheral surface.The nip rolls 34,36 are mounted to the base frame 12 at the adjustableconnecting means on parallel horizontally extending and horizontallyspaced apart axes with the peripheral surfaces of the rolls 34,36 spacedapart a predetermined distance to form a narrow gap 38 of predeterminedwidth corresponding to the desired overall thickness of the lenticularmaterial 100. The rolls 34,36 have respective shafts 35 extending fromopposite ends thereof, and the shafts 35 are mounted in the connectingmeans, preferably pillow blocks. The pillow blocks are mounted so as tobe adjustably positionable with respect to one another by suitablemeans, such as a threaded shaft (not shown). By suitable adjustment ofthe connecting means, the spacing or position between the peripheralsurfaces of the rolls 34,36 can be adjusted to thereby control the widthof the narrow gap 38, and thus the thickness of the composite material100 which is produced. Preferably, The lenticular material 100 is of apredetermined thickness less than the width of the narrow gap 38 betweenthe nip rolls 34,36.

Suitable drive means (not shown), such as a gear train, cooperates withthe shafts 35 and serves for rotating the nip rolls 34,36 at asubstantially equal peripheral speed and in opposite directions ofrotation. The horizontally-extending axes of the nip rolls 34,36 arelaterally offset from one another such that the peripheral surface ofeach nip roll moves in a generally downward direction as it passesthrough the narrow gap 38.

Mounted below the cylindrical roll 26 to the base frame by secondaryconnecting means (not shown) is a UV reservoir pan 40 operable forretaining a resin 41 which coats the roll 26 as it rotates. The UVreservoir pan 40 applies to the exposed surface of the roll 26 a coatingpreferably of flowable uncured thermosetting resin. The UV reservoir pan40 is defined by a series of retaining walls which closely conform tothe outer peripheral surface 28 of the cylindrical roll 26. Thegenerally upward movement of the peripheral surface 28 of the roll 26,together with the viscosity of the resin 41 prevents any substantialleakage of the resin 41 from the juncture between the retaining wallsand the peripheral surface 28 of the roll 26. Connected to the UVreservoir pan 40 and pressured against the peripheral surface 28 of thecylindrical roll 26 is a doctor blade 42 or other control means. Thedoctor blade 42 is operable for maintaining or controlling coatingthickness on the cylindrical roll 26.

As seen in FIG. 1, the rigid material 100 is first directed from thefeed side 16 through the narrow gap 38 of the first pair of nip rolls34. After passing through the narrow gap 38 between the first pair rolls34, the material 100 comes in contact with the coated peripheral surface28 of the cylindrical roll 26. The coating 41 is thus located in contactwith the surface 28 of the roll 26 and beneath the material 100. As thematerial 100 advances around the periphery 28 of the cylindrical roll 26with the coating 41 in contact with the patterned relief surface of theroll 26, the uncured resin 41 is hardened and cured by exposure to acuring agent. Where an actinic radiation curable resin is used, thecuring agent may comprise electron beam radiation or ultraviolet light.As illustrated, UV lamps 30 are located closely adjacent the cylindricalroll 26 and are oriented toward the roll 26 for directing ultravioletlight through the material 100 and into contact with the uncuredflowable resin 41 therebelow. Exposure of the coating resin 41 to the UVradiation causes the resin 41 to cure and harden quickly so that by thetime the resin coating 41 is separated from the molding surface of thecylindrical roll 26 it is in a hardened and shape sustaining state andaccurately reproduces the pattern of the molding surface in the outersurface of the resin 41. The protective entrapment of the resin 41between the material 100 and the roll 26 keeps the uncured resin 41 outof contact with the oxygen present in the ambient air and thus avoidsthe necessity of inert gas blanketing of the uncured resin as isconventionally needed in UV curing systems.

The UV lamps 30 are preferably located in a protective housing which fitclosely above the periphery 28 of the cylindrical roll 26 so as toshield persons in the vicinity of the apparatus 10 from unwantedexposure to the ultraviolet light. As previously stated, the cylindricalroll 26 may, for example, have a relief patterned surface texture forproducing various relief patterns in the surface of the lenticularmaterial 100; or if desired, the cylindrical roll 26 may have a highlypolished surface texture for producing a high quality blemish-free glosssurface without the surface imperfections often found in coatings whichare dried or cured in contact with air or gas.

Joined to the base frame 12 and extending around a portion of theperiphery of the cylindrical roll 26 is a dark plate 32 for preventingexposure of the roll 26 to the radiation exposed by the UV lamp 30. Thedark plate 32 is operable for protecting the roll 26 from the radiation,thereby preventing distortion of the relief pattern engraved thereon.Further, light shields 33 are provided for added protection.

As indicated above, the coating thickness of the roll 26 is controlledby the doctor blade 42 and doctor blade pressure as opposed to theparallelism and roll uniformity plus bearing accuracy as taught by theprior art. Advantageously, by not having to rely on roll accuracyproduction of material, large material widths are possible. Coatingthickness is usually little more than the depth of the pattern as thedoctor blade 42 rides and wipes from the high points on engravedpattern. The doctor blade 42 is preferably of rubber or plasticconstruction such as high density polyethylene, nylon, polyurethane.However, it will be understood by those skilled in the art that othermaterials resistant to the coating composition. The doctor blade 42 mayoptionally be backed with a metal or other hard material bar to giveadditional rigidity and straightness which is needed for long lengthwhen producing a wide sheet. Further, it will be appreciated by thoseskilled in the art that while the thickness of the material 100 may varyto some extent, the thickness of the coating of resin 41 applied to thematerial 100 will compensatingly vary so that the overall thickness ofthe material 100 plus resin 41 coating is always uniform and correspondsto the predetermined spacing of the narrow gap 38. It will also beunderstood by those skilled in the art that the doctor blade 42 mayoptionally be a nip roll or a wire wound metering rod.

After passing across the cylindrical roll 26, the material 100 passesthrough the second pair of nip rolls 36 at the narrow gap 38 onto thetake up side 18. As the coating 41 and material 100 passes through thenarrow gap 38 of the second pair of nip rolls 36, the rolls 36 and gap38 serve to further meter the coating 41 so as to define a predeterminedthickness for the material 100 plus the coating 41 which corresponds tothe width of the narrow gap 38. Importantly, by using the disclosedapparatus and method 10, rigid sheets may be produced having a varietyof widths and thicknesses up to ¼ inch.

Referring now to FIG. 2, a preferred embodiment of the disclosedapparatus 10 and method 10 of the present invention is shown wherein athin flexible web material 200 is produced. Generally, the apparatus 10comprises a base frame 12 having a generally table like configurationincluding an upper surface 14 and opposing sides, 16 and 18respectively, defining a central or intermediate opening 20. Theopposing sides operate to function as a feed side 16 and a take up side18. The feed side 16 is provided with the addition of a flexible thinweb unwind roll 50. Further, the take up side 18 is provided with theaddition of a flexible, thin patterned web wind up roll 52. The baseframe 12 also includes a plurality of legs, 22 and 24 respectively, forsupporting the base frame 12 at a pre-determined height and adjustable,connecting means (not shown) operable for use with a plurality of rolls.The legs 22, 24 are preferably adjustable in height such that they canbe raised or lower as desired or required. Further, the central orintermediate opening 20 may be widened or narrowed as required. Disposedwithin the intermediate opening 20 and mounted to the base frame 12along a substantially horizontal axis by the adjustable, connectingmeans is an elongate engraved, patterned cylindrical roll 26 forembossing the lenticular material 200 with a pre-determined reliefpattern.

The cylindrical roll 26 preferably has respective shafts 25 extendingfrom opposite ends thereof (not shown), and the shafts 25 are mountedinto the connecting means. The connecting means are preferably pillowblocks that are adjustable in position by suitable means, such as athreaded shaft (not shown). By suitable adjustment of the connectingmeans, the cylindrical roll 26 can be raised or lowered, but ispreferably fixed, in position relative to the upper surface 14 of thebase frame 12. Also, connected to the roll 26 is suitable drive means(not shown), such as a gear train or belt train, for cooperating withthe shafts 25 and rotating the roll 26 at a pre-determined speed in apredetermined direction. In the embodiment illustrated herein, thecylindrical roll 26 is mounted such that a peripheral surface 28 thereofis substantially planar with the upper surface 14 of the base frame 12.

At least one pair, and preferably two pairs, of nip or guides rolls, 34and 36 respectively, are mounted to the base frame 12 on the opposingsides 16,18. The nip rolls 34,36 are generally of an elongatecylindrical shape and have a substantially smooth peripheral surface.The nip rolls 34,36 are mounted to the base frame 12 at the adjustableconnecting means on parallel horizontally extending and horizontallyspaced apart axes with the peripheral surfaces of the rolls 34,36 spacedapart a predetermined distance to form a narrow gap 38 of predeterminedwidth corresponding to the desired overall thickness of the lenticularmaterial 100. The rolls 34,36 have respective shafts 35 extending fromopposite ends thereof, and the shafts 35 are mounted in the connectingmeans, preferably pillow blocks. The pillow blocks are mounted so as tobe adjustably positionable with respect to one another by suitablemeans, such as a threaded shaft (not shown). By suitable adjustment ofthe connecting means, the spacing or position between the peripheralsurfaces of the rolls 34,36 can be adjusted to thereby control the widthof the narrow gap 38, and thus the thickness of the composite material200 which is produced. Preferably, The lenticular material 200 is of apredetermined thickness less than the width of the narrow gap 38 betweenthe nip rolls 34,36.

Suitable drive means (not shown), such as a gear train, cooperates withthe shafts 35 and serves for rotating the nip rolls 34,36 at asubstantially equal peripheral speed and in opposite directions ofrotation. The horizontally-extending axes of the nip rolls 34,36 arelaterally offset from one another such that the peripheral surface ofeach nip roll moves in a generally downward direction as it passesthrough the narrow gap 38.

Mounted below the cylindrical roll 26 to the base frame by secondaryconnecting means (not shown) is a UV reservoir pan 40 operable forretaining a resin 41 which coats the roll 26 as it rotates. The UVreservoir pan 40 applies to the exposed surface of the roll 26 a coatingpreferably of flowable uncured thermosetting resin. The UV reservoir pan40 is defined by a series of retaining walls which closely conform tothe outer peripheral surface 28 of the cylindrical roll 26. Thegenerally upward movement of the peripheral surface 28 of the roll 26,together with the viscosity of the resin 41 prevents any substantialleakage of the resin 41 from the juncture between the retaining wallsand the peripheral surface 28 of the roll 26. Connected to the UVreservoir pan 40 and pressured against the peripheral surface 28 of thecylindrical roll 26 is a doctor blade 42 or other control means. Thedoctor blade 42 is operable for maintaining or controlling coatingthickness on the cylindrical roll 26.

A feed roll 54 is mounted at connecting means (not shown) adjacent tothe peripheral surface 28 of the cylindrical roll 26 for directing orfeeding the web material 200 around a predetermined arcuate length ofthe peripheral surface 28 of the cylindrical roll 26. Further, a peeloff roll 56 is mounted to the base frame 12 at connecting means (notshown) adjacent to the peripheral surface 28 of the cylindrical roll 26for peeling off the web material 200 from the roll 26 after it passesacross the surface 28. Preferably, the feed roll 54 and the peel offroll 56 are located on opposing, but corresponding sides of thecylindrical roll 26.

As seen in FIG. 2, the thin, flexible material 200 is first directedfrom the feed roll 54 to the feed side 16 through the narrow gap 38 ofthe first pair of nip rolls 34. After passing through the narrow gap 38between the first pair rolls 34, the material 200 advances around theperipheral surface of the feed roll 54. Thereafter, the material 200comes in contact with the coated peripheral surface 28 of thecylindrical roll 26. The coating 41 is thus located in contact with theperipheral surface 28 of the roll 26 and beneath the material 200. Asthe material 200 advances around the periphery 28 of the cylindricalroll 26 with the coating 41 in contact with the patterned relief surfaceof the roll 26, the uncured resin 41 is hardened and cured by exposureto a curing agent. Where an actinic radiation curable resin is used, thecuring agent may comprise electron beam radiation or ultraviolet light.

As illustrated, UV lamps 30 are located closely adjacent the cylindricalroll 26 and are oriented toward the roll 26 for directing ultravioletlight through the material 200 and into contact with the uncuredflowable resin 41 therebelow. Exposure of the coating to the UVradiation causes the resin 41 to cure and harden quickly so that by thetime the resin 41 is separated from the molding surface of the roll 26it is in a hardened and shape sustaining state and accurately reproducesthe pattern of the molding surface in the outer surface of the resin 41.The protective entrapment of the resin 41 between the material 200 andthe roll 26 keeps the uncured resin 41 out of contact with the oxygenpresent in the ambient air and thus avoids the necessity of inert gasblanketing of the uncured resin 41 as is conventionally needed in UVcuring systems.

The UV lamps 30 are preferably located in a protective housing which fitclosely above the periphery 28 of the cylindrical roll 26 so as toshield persons in the vicinity of the apparatus from unwanted exposureto the ultraviolet light. As previously stated, the cylindrical roll 26may, for example, have a relief patterned surface texture for producingvarious relief patterns in the surface of the lenticular material 200;or if desired, the cylindrical roll 26 may have a highly polishedsurface texture for producing a high quality blemish-free gloss surfacewithout the surface imperfections often found in coatings which aredried or cured in contact with air or gas.

Joined to the base frame 12 and extending around a portion of theperiphery of the cylindrical roll 26 is a dark plate 32 for preventingexposure of the roll 26 to the radiation exposed by the UV lamp 30. Thedark plate 32 is operable for protecting the roll 26 from the radiation,thereby preventing distortion of the relief pattern engraved thereon.Further, light shields 33 are provided for added protection.

As indicated above, the coating thickness of the material 200 iscontrolled by the doctor blade 42 and doctor blade pressure and not theparallelism and roll uniformity plus bearing accuracy as taught by theprior art. Advantageously, by not having to rely on roll accuracyproduction of material, large widths is possible. Coating thickness isusually little more than the depth of the pattern as the doctor blade 42rides and wipes from the high points on engraved pattern. The doctorblade 42 is preferably of rubber or plastic construction such as highdensity polyethylene, nylon, polyurethane. However, it will beunderstood by those skilled in the art that other materials resistant tothe coating composition. The doctor blade 42 may optionally be backedwith a metal or other hard material bar to give additional rigidity andstraightness which is needed for long length when producing a wide web.Further, it will be appreciated by those skilled in the art that whilethe thickness of the material 200 may vary to some extent, the thicknessof the coating of resin 41 applied to the material 200 willcompensatingly vary so that the overall thickness of the material 200plus resin 41 coating is always uniform and corresponds to thepredetermined spacing of the narrow gap 38. It will also be understoodby those skilled in the art that the doctor blade 42 may optionally be anip roll or a wire wound metering rod.

After passing across the cylindrical roll 26, the material 200 andcoating 41 passes around the periphery of the peel off roll 56 andthrough the second pair of nip rolls 36 at the narrow gap 38 onto thetake up side 18. As the coating 41 and material 200 passes through thenarrow gap 38 of the second pair of nip rolls 36, the rolls 36 and gap38 serve to further meter the coating 41 so as to define a predeterminedthickness for the material 200 plus the coating 41 which corresponds tothe width of the narrow gap 38. Subsequent to passing along the take upside, the web material 200 is wound around the flexible, thin patternedwind up roll 52. Importantly, by using the disclosed apparatus andmethod 10, flexible thin webs may be produced having a variety of widthsand thicknesses down to 0.001 inches or less.

With the selection of a stable, yet flexible material 200, a stableuniform patterned web is possible. A stable uniform web is not possiblewith an extruded web where the pattern is imparted to the thin web whenthe resin is molten. Since the pattern is cured from a liquid andsolidified against the patterned roll, an accurate reproduction of thepattern is possible, which is not by extrusion. There is no heatrequired to form the pattern or initiate the cure or solidification ofthe liquid formulation.

Thin patterned web or sheet material 200 can be produced on presentinvention in continuous lengths or sheeted at the end of the machine byexposure of UV light through the material 200. The material 200 isoptionally treated or pre-coated to bond to the cured resin. Thematerial 200 can have a pressure sensitive adhesive or ink receptivecoating pre coated on the opposite or back side thereof with a clearrelease liner. The adhesive coated patterned sheet can be laminated toanother web or sheet material by removing the release liner andlaminating through a nip roll. The ink receptive coating may be used toapply an image from an inkjet printer directly to the material 200.

The apparatus of the present invention provides a dual purpose in thatboth rigid pre extruded or cast sheet can be manufactured as well asthin flexible film or web. The apparatus permits this dual manufactureby providing the connecting means operable for receiving additionalrolls. Further, as stated the connecting means are adjustablypositionable such that the rolls can be manipulated into variouspositions to accommodate both thick, rigid sheet material and thin,flexible material. Heretofore, the prior art fails to provide suchversatility, in that separate distinct machines were required for themanufacture of lenticular material having rigid or flexible properties.Further, and advantageously, test runs for certain materials andpatterns can now be performed more cost effectively and efficiently.

Referring now to FIG. 3, the newly patterned web material 200 may beoptionally laminated to a thick rigid sheet 300 by using the apparatus10 of the present invention. The optional lamination of a rigid sheet300 is performed by the addition of laminator nip rolls 58, an unwind ofpatterned sheet with pressure sensitive adhesive thereon 62, directing arigid sheet 300 through the nip rolls 58 such that the patterned sheetis adhered thereto, and a release liner take up roll 60.

Referring now to FIGS. 4 and 5, an alternative embodiment of the presentinvention is shown wherein a thin, flexible patterned web 200 isproduced. As shown, a base frame 12 having first and second ends 62 and64 including a plurality of adjustable legs, 66, 68, 69, 70, 71 and 72respectively, a plurality of adjustable cross members, 74, 76, 78, and80 respectively, and at least one vertical member 81 is provided.Attached to the respective first and second ends 62,64 of the base frame12 at the adjustable legs 66,68, 69,70, 71 and 72, are a feed roll 54and a take up roll 56 for a flexible web. The feed roll 54 and take uproll 56 are attached or mounted to the legs by a connecting means 95.The connecting means 95 are preferably pillow blocks that are adjustablein position by suitable means. However, it will be understood by thoseskilled in the art that spacers may be used as well.

Further, attached to the cross members 74,76,78, and 80 by theconnecting means 95 in a predetermined location is an engraved,patterned cylindrical roll 26. The cylindrical roll 26 is situated suchthat the peripheral surface 28 thereof extends above an upper surface 14of the base frame 12. The cylindrical roll 26 preferably has respectiveshafts 25 extending from opposite ends thereof, and the shafts 25 aremounted to the connecting means 95. Also, connected to the roll 26 issuitable drive means (not shown), such as a gear train or belt train,for cooperating with the shafts 25 and rotating the roll 26 at apre-determined speed in a predetermined direction.

In addition, located on the cross members 74, 76, 78, and 80 inpredetermined locations, at predetermined heights are a plurality of nipor guide rolls, 82, 84, 86 and 88 respectively, for directing theflexible web 200 from the feed roll 54 through the apparatus 10, aroundthe engraved, patterned cylindrical roll 26 to the take up roll 56. Thenip rolls 82, 84, 86 and 88 are generally of an elongate cylindricalshape and have a substantially smooth peripheral surface. The nip rolls82, 84, 86 and 88 are mounted to the base frame 12 at the adjustableconnecting means 95 on parallel horizontally extending axes. The rolls82, 84, 86 and 88 have respective shafts 35 extending from opposite endsthereof, and the shafts 35 are mounted in the connecting means 95,preferably pillow blocks. The pillow blocks are mounted so as to beadjustably positionable with respect to one another by suitable means,such as a threaded shaft (not shown). By suitable adjustment of theconnecting means 95, the spacing or position between the peripheralsurfaces of the rolls 82, 84, 86 and 88 can be adjusted. Additionally,spacers may be provided to adjust the height of the rolls 82, 84, 86 and88. By way of example, the rolls 82, 84, 86 and 88 may be adjusted suchthat the peripheral surfaces thereof are coincident with the peripheralsurface 28 of the cylindrical roll 26. By making such an adjustment, theapparatus can accommodate a rigid sheet in addition to a flexible web.Suitable drive means (not shown), such as a gear train, cooperates withthe shafts 35 and serves for rotating the nip rolls 82, 84, 86 and 88 ata substantially equal peripheral speeds of rotation.

Mounted below the cylindrical roll 26 to the base frame by secondaryconnecting means (not shown) is a UV reservoir pan 40 operable forretaining a resin which coats the roll 26 as it rotates. The UVreservoir pan 40 applies to the exposed surface of the roll 26 a coatingpreferably of flowable uncured thermosetting resin. The UV reservoir pan40 is defined by a series of retaining walls which closely conform tothe outer peripheral surface 28 of the cylindrical roll 26. Thegenerally upward movement of the peripheral surface 28 of the roll 26,together with the viscosity of the resin prevents any substantialleakage of the resin from the juncture between the retaining walls andthe peripheral surface 28 of the roll 26. Connected to the UV reservoirpan 40 and pressured against the peripheral surface 28 of thecylindrical roll 26 is a doctor blade 42 or other control means. Thedoctor blade 42 is operable for maintaining or controlling coatingthickness on the cylindrical roll 26.

Located above the engraved, patterned cylindrical roll 26 and affixed toa vertical member 81 are UV lamps 30 for radiating the flexible web 200and coating as it crosses over a peripheral surface 28 of thecylindrical roll 26. By radiating the flexible web 200 and coating, thepatterned relief of the cylindrical roll 26 is transferred to the web200.

As shown in FIG. 4, the nip or guide rolls 82, 84, 86, and 88 are spacedapart at a predetermined distance for directing the flexible web 200through the apparatus 10. It will be understood by those skilled in theart, that by adjusting the connecting means 95 on the cross members 74,76, 78 and 80, one can manipulate the cylindrical roll 26 and the nip orguide rolls 82, 84, 86 and 88 to accommodate a rigid sheet 100 asopposed to the thin, flexible web 200 (see, FIG. 6).

In all of the above referenced embodiments, during the operation of theapparatus of the present invention, the cylindrical roll 26 is heated byexposure to the ultraviolet radiation from the UV lamps 30 and by heatgenerated from an exothermic reaction which takes place during thecuring of the resin. In order to remove the heat from the cylindricalroll 26 and to maintain the peripheral surface 28 thereof at a desirableoperating temperature, an optional means may be provided for circulatinga liquid coolant through a hollow interior of the roll 26. Preferably,the optional means may include a liquid cooling unit having supply andreturn conduits interconnecting with the cooling unit for circulatingthe coolant into and through the roll 26.

The foregoing is a description of the various embodiments of the presentinvention that are provided here by way of example only. Although theapparatus and method of the present invention has been described withreference to the preferred embodiments and examples thereof, otherembodiments and examples may perform similar functions and/or achievesimilar results. All such equivalent embodiments and examples are withinthe spirit and scope of the present invention and are intended to becovered by the appended claims. Although specific terms are employedherein, they are used in a generic and descriptive sense only and notfor purposes of limitation.

1. A method for producing a lenticular material having a predeterminedsurface characteristic of high quality and definition formed on one sidethereof, said method comprising: providing a rotating, engravedcylindrical roll, advancing a material along a predetermined path oftravel while directing one surface of the material into contact with aperipheral surface of the rotating, engraved cylindrical roll, applyingto the peripheral surface of the roll a coating of a uncured resin, suchthat the coating is located about the roll and beneath the material,controlling the thickness of the coating, curing the resin coated aboutthe material, and directing the material with the cured resin thereonaway from the rotating cylindrical roll.
 2. The method as set forth inclaim 1, wherein the uncured resin is a flowable uncured thermosettingresin.
 3. The method as set forth in claim 1, wherein the step of curingthe resin includes directing ultraviolet light toward the peripheralsurface of the cylindrical roll having the material thereon.
 4. Themethod as set forth in claim 1, wherein the step of controlling thethickness of the coating includes the use of a control mechanism. 5 .The method as set forth in claim 4, wherein the control mechanism is adoctor blade.
 6. The method as set forth in claim 1, wherein thematerial is a thin, flexible web.
 7. The method as set forth in claim 1,wherein the material is a rigid composite sheet.
 8. The method as setforth in claim 1, wherein the material is directed along a path oftravel by a plurality of adjustable, rotating nip rolls.
 9. The methodas set forth in claim 1, further including the step of metering thecoated material to a predetermined thickness after the material isdirected away from the roll.
 10. The method as set forth in claim 9,wherein the material is metered by a pair of nip rolls.
 11. The methodas set forth in claim 6, wherein the material produced has a thicknessof 0.001 inches or less.
 12. The method as set forth in claim 7, whereinthe material produced has a thickness up to ¼ inch.
 13. The method asset forth in claim 9, further including laminating the material producedto a rigid sheet.